Polyurethane composition and process



United States Patent Of 3,407,153 POLYURETHANE COMPOSITION AND PROCESS Russel A. Bowman, Clarence, and Bruce N. Wilson,

Niagara Falls, N.Y., assignors to Hooker Chemical Corp oralgion, Niagara Falls, N.Y., a corporation of New No Drawing. Continuation-impart of application Ser. No. 155,832, Nov. 29, 1961. This application June 30, 1966, Ser. No. 561,767

4 Claims. (Cl. 260-25) ABSTRACT OF THE DISCLOSURE Polyurethane compositions and foams are prepared by reacting organic polyisocyanates and polyether or polyester resins in the presence of a catalyst composition comprising a metal alcoholate and a carrier therefor, prepared by reacting together an alcohol having at least three hydroxyl groups, and at least one antimony or bismuth compound, wherein the reaction mixture contains the alcohol and the antimony or bismuth compound in a ratio which provides at least 1.5 moles of the alcohol for each unit atomic weight of the metallic element. The alcohol is present in an amount to provide a reaction medium during the reaction and to act as a carrier for the resultant reaction product.

This is a continuation-in-part of application Ser. No. 155,832, filed Nov. 29, 1961, now abandoned.

This invention relates to the preparation of urethane compositions and foams by processes which use an improved catalyst composition, and to the products produced thereby.

Substantially pure, novel organic compounds of antimony and bismuth have been prepared recently having the following structural formulae:

wherein R is selected from the group consisting of hydrogen, alkyl, substituted alkyl, aryl, substituted aryl, and mixtures thereof, and M is a metal selected from the group consisting of antimony and bismuth. Such compounds are disclosed in United States Patent No. 3,109,853.

The above compounds are highly crystalline and of such limited solubility in ordinary solvents that their purification has been limited to sublimation as a final purification step, and the entire purification process has been so involved that the expense of pure compounds is prohibitively high. Nevertheless, the purification steps have been considered to be essential heretofore in order to produce a pure specific compound that would be useful for many purposes normally requiring a pure known substance. For instance, one large use for the above antimony and bismuth compounds that heretofore was thought to yield better results in the form of a specific pure substance is as a catalyst for various organic reactions, such as in the preparation of urethane foams and in oxyalkylation reactions.

It has been discovered that a composition consisting essentially of an unpurified reaction product and a carrier therefor prepared by reacting together an excess of cer- Patented Oct. 22, 1968 tain alcohols with certain antimony and bismuth compounds to be described in detail hereinafter is entirely satisfactory for use as a catalyst in organic reactions where the above-described pure known compounds of antimony and bismuth were used heretofore. As is well known, even small amounts of impurities will often radically affect a catalyst and in turn the progress of the catalyzed reaction, and thus the above discovery is surprising and unexpected in view of the teachings of the art.

It is an object of the invention to provide an improved process for preparing polyurethane compositions, including foams, wherein the catalyst comprises the improved catalyst composition of the invention.

Still other objects and advantages of the present invention will be apparent to those skilled in the art upon reference to the following detailed description and the examples. In accordance with the present invention, a catalytic composition consisting essentially of a reaction product and a carrier therefor is prepared by reacting together an alcohol having at least three hydroxyl groups selected from the group consisting of:

and at least one compound containing a metallic element selected from the group consisting of antimony and hismuth, wherein R is a noninterfering substituent selected from the group consisting of hydrogen, halogen, alkyl, substituted alkyl, aryl, substituted aryl and mixtures thereof. The alkyl or aryl groups may contain, for example, 1-20 carbon atoms and preferably 1-8 carbon atoms when the group is alkyl. The preferred substituted alkyl and aryl groups are the hydroxyalkyl and hydroxyaryl groups. The reaction mixture consists essentially of the alcohol and the compound containing a metallic element in a ratio providing substantially more than one mole of the alcohol for each unit atomic weight of the metallic element and preferably the alcohol is present in an amount to provide a reaction medium during the reaction and to act as a carrier for the resultant reaction product. The reaction mixture after completing the reaction contains excess unreacted alcohol as the carrier for the reaction product and the reaction product is present therein.

It is not necessary that the reaction mixture be purified and the resultant antimony or bismuth compound be isolated in the pure state before use as a catalyst. It has been discovered that the unpurified reaction mixture is entirely satisfactory for use as a catalytic composition in catalyzing organic reactions of the same type for which the pure antimony and bismuth compounds described herein have been used heretofore, and in fact the reaction mixture is often preferable to the pure compound. For instance, surprisingly the crude reaction mixture containing the resultant organic antimony or bismuth compound present in an excess of the alcohol reactant will dissolve much more readily in the reaction mixture to be catalyzed and often without formation of a two phase system as is true with the pure antimony or bismuth compounds. Thus, using the composition of the present invention as a catalyst assures more predictable, reproducible and trouble free results in the catalyzed process as well as allowing the catalyst to be produced at a much lower cost.

Illustrative alcohols which can be used in the present invention include pentaerythritol, dipentaerythritol, polypentaerythritol, trimethylolpropane, trirnethylolethane, trimethylolbutane, trimethylolisobutane, trimethylolpentane, trimethylolhexane, trimethyloloctane, trimethylolnonane, trimethylolundecane, trimethylolheptadecane, trimethylolpropene, trimethylolbutene, trimethylolpentene, glycerol, sorbitol, hexanetriol, butanetriol, and the like. The foregoing alcohols may be substituted with noninterfering substituents such as chlorine, bromine, fluorine, iodine, alkyl, and aryl substituents such as phenyl, naphthyl, etc. When a trimethylolalkane is employed, the alkyl group preferably contains 1-10 carbon atoms, although up to or carbon atoms may be used in some instances. l,2,3-trihydroxy-2-phenylpropane can be used.

Typical trivalent antimony or bismuth compounds which can be employed in the present invention include antimony trioxide, antimony trichloride, antimony oxychloride, bismuth trioxide, bismuth trichloride, bismuth oxychloride, and a compound having the following structural formula:

wherein M is antimony or bismuth and R is an anion of an alcoholate preferably having less than 13 carbon atoms. Among the latter compounds are esters made by reacting an epoxide with antimony or bismuth trichloride to produce a beta-chloro antimonous acid or a betachloro bismuthous acid. Specific examples of these betachloro compounds are tris(2-chl0roethyl)antimonite, tris(2-chlorobutyl)antimonite, tris(2 chloro-2-phenylethyl)antimonite, tris(2-chloroethyl)bismuthite, tris(2-chloropropyl)bismuthite, etc. Other esters include those made by the reaction of organic monohydroxy compounds with antimony or bismuth trioxide, such as tris(2-ethylhexyl) antimonite, tris(n-octyl)antimonite, tribenzyl antimonite, triphenyl antimonite, tris(Z-ethylhexyl)bismuthite, tris (n-octyl)bismuthite, tribenzyl bismuthite, triphenyl bismuthite and the like.

The time and temperature of reaction are not critical and will vary depending upon the reactants employed, degree of completion of reaction desired, etc. Usually, the reaction can be continued from about 10 minutes to 10 to hours or longer at a temperature of about -300 C., and preferably from about 45 minutes to about 4 hours, at a temperature of about 130-210 C. At higher reaction temperatures shorter reaction times may be employed, and vice versa. The reaction product thereby obtained may not be purified, and the entire reaction mixture may be used as a catalyst composition.

The alcohol reactant is employed in substantial excess of that amount theoretically required to react with the antimony or bismuth compound. The amount of this excess may vary over wide ranges, but generally it is desired that the reactant be present in a ratio of at least 1.5 and preferably two to four or more moles of the alcohol for each unit atomic weight of antimony or bismuth employed as a reactant. The alcohol should be present in the reaction mixture in an amount to provide a reaction medium during the reaction and to act as a carrier for the reaction product after completing the reaction. A preferred method of operation is to prepare the antimony or bismuth ester directly "in the alcohol component to be used in the preparation of a resin. In this way a separate catalyst preparation step is eliminated. The catalyst component can be prepared in the course of heating the alcohol component. Hence, it is evident that extremely large molar ratios of alcohol to metallic compound are contemplated, even 100 to 1 and greater.

A solvent is not necessary and it is preferred that the excess alcohol reactant be used as the solvent. However, if it is desired a solvent may be used provided it is inert and it does not detrimentally affect the reaction product or its use as a catalyst. A solvent may have a boiling point above C. and it should be substantially unreactive with the reactants or reaction products under the condition of the reaction, and it should not form stable reaction products under the conditions of the reaction.

The process of the present invention is highly satisfactory for the preparation of reaction mixtures from an alcohol such as trimethylolpropane, trimethylolethane, glycerol, and pentaerythritol, and an antimony or bismuth compound mentioned herein. Reaction mixtures prepared from an antimony compound and trimethylolpropane are often preferred catalysts for use in organic reactions, including formulations for foam alkyds or urethane foams, oxyalkylation reactions, etc. The process of the invention is capable of preparing unpurified reaction mixtures from an antimony compound and trimethylolpropane in excellent yield and the resultant product is as satisfactory as pure trimethylolpropane antimonite in the catalysis of organic reactions.

The process described herein is especially useful in the preparation of reaction mixtures from antimony or bismuth compounds and normally solid polyalcohols such as trimethylolpropane. The trimethylolpropane is present in excess in the molten reaction mixture and, upon completion of the reaction at elevated temperature, the trimethylolpropane-antimony reaction product is dissolved in the excess molten trimethylolpropane which acts as a solvent or suspension medium. By cooling the reaction mixture to a point where it is viscous but still pourable, the reaction product separates out in the form of fine crystals which are held in uniform suspension. The viscous reaction mixture then may be solidified quickly so as to form a solid material with fine crystals of the reaction product distributed substantially uniformly therethrough. The solid product may be ground to particles of a desired size, and it is in a very convenient form for use as a catalyst.

During the reaction in instances where an oxide of the desired metal is used, the water of reaction may be removed by distillation, or preferably by distillation under reduced pressure. For instance, a reduced pressure of about 2030 millimeters of mercury absolute at a reaction temperature of about -185 C. has been found to be very satisfactory when preparing a reaction mixture from trimethylolpropane and an antimony compound. However, other temperatures of reactions and other reduced pressures may be selected as necessary to assure the removal of the water of reaction efiiciently and to provide a reaction mixture at the completion of the reaction which is substantially free of Water. In such instances, it is desirable that the reaction be continued at the reaction temperature and under the reduced pressure until water is no longer removed.

When catalyzing organic reactions with the composition of the invention, there is usually no need to change prior art practice with the exception of substituting the catalyst composition of the invention for the pure antimony of bismuth compounds formerly used for this purpose. For example, urethane foams may be prepared following prior practice with the exception of reacting the polyethers and/or alkyd resins together with a poly-isocyanate in the presence of a catalytic amount of the catalyst composition of the invention. Similarly, where an active hydrogen-containing material containing hydroxyl groups is reacted together with an alkylene oxide to produce the oxyalkyl derivative, the prior art practice need be changed only to the extent of substituting a catalytic amount of the catalyst composition of the invention for the catalyst previously used.

The nature of the alcohol-metallic compound reaction product which is present in the reaction mixture is not fully understood at the present time. However, it is known that when the metallic compound is an oxide, water of reaction is given off and presumably the reaction is between the hydroxyl groups of the alcohol and the metallic element to form linkages, where M is the metallic element. Since an excess of alcohol is used it is not possible at this time to say whether or not the metallic element is attached to only one oxygen atom or more of any given alcohol molecule to satisfy its trivalent nature. It is possible that the metallic element is attached to up to three separate alcohol molecules through the above described linkages, and that this explains the marked increase in solubility and other favorable characteristics of the reaction product of the invention.

The foregoing detailed description and the following specific examples are for purposes of illustration only, and are not intended to limit the invention.

EXAMPLE 1 This example illustrates the preparation of a reaction product in accordance with the present invention from antimony trioxide and glycerol which is suitable for use as a catalyst in organic reactions.

16 moles of glycerine and 1 mole of antimony trioxide are charged to a 3 liter, B-necked flask. The temperature is raised to 160 C., at which temperature water is driven olf and the reaction proceeds. When the Water ceases to exude, a vacuum is applied to remove additional quantities of reaction water. When further water ceases to exude, the vacuum is broken with inert gas. The resultant product is decanted, cooled, and stored for use as a catalyst without further purification or removal of the excess glycerol.

EXAMPLE 2 This example illustrates the preparation of a catalyst which is the reaction product of antimony trioxide and trimethylolpropane.

Reactants are charged to a typical resin reactor (glass or stainless steel) in the molar ratio of 4 moles of trimethylolpropane to 1 mole of antimony trioxide (Sb O Heat is applied and the charge melts. As the charge melts, agitation is applied, and thereafter the temperature is raised to 160185 C. Vacuum (-30 millimeters of mercury absolute) is applied toremove the reaction water as the reaction proceeds.

When the water of reaction ceases to exude, the vacuum is broken with inert gas and the reaction product is cooled to a point where a thick slurry exists (90-120 C.). The reaction product without further purification is then discharged into a suitable container such as a steel container where it is allowed to cool to room temperature. Subsequently, the product is coarsely ground for use as a catalyst without further purification being necessary.

It is desirable to decant the reactor contents at the thick slurry stage so that phase separation of the reaction product, which is in the form of crystals suspended in the fused excess unreacted trimethylolpropane carrier, does not occur during periods of no agitation. When this is done, clear needle-like crystals of the reaction product of trimethylolpropane and antimony trioxide may be seen distributed uniformly throughout the solidified trimethylolpropane carrier. Thus, a substantially uniform homogeneous product is produced which is highly useful as a catalyst.

EXAMPLE 3 Using the same procedure as described in Example 2, a catalyst composition is prepared by reacting six moles of trimethylolethane and one mole of antimony trioxide.

EXAMPLE 4 35.5 moles of pentaerythritol and 17.7 moles of antimony trioxide are mixed and gradually heated to the temperature range of one hundred and sixty to one hundred and sixty-five degrees centigrade. Vacuum (about twentythree millimeters of mercury absolute) is applied for one hour and ten minutes. The distillation of water begins at one hundred and sixty-two degrees centigrade. When the water of reaction has been removed, the reaction product is discharged into a suitable container where it is allowed to cool to room temperature.

EXAMPLE 5 This example illustrates the application of the princlples of this invention to a commercial polyhydric component, a polyoxy propylene derivative of trimethylolpropane having the following structural formula a CHz-(OCH;CH):OH

CH3 oH3om-c-cH2(0om-(:H- ,orr

CH; CHz-(OOHz( JH).OH Twenty moles of pentaerythritol, 12.2 moles of the aboveidentified commercial polyoxy propylene derivative of trimethylolpropane are blended with ten moles of antimony trioxide and gradually heated to the temperature range of one hundred and sixty to one hundred and seventy degrees centigrade. Vacuum (twenty to twentyfive millimeters of mercury absolute) is maintained on the reaction mixture for two hours and fifteen minutes to insure complete removal of the water of reaction. The reaction product is discharged into a suitable container and allowed to cool to room temperature.

Using the procedures of the foregoin examples, bismuth compounds corresponding to these antimony compounds are prepared using the ratios of alhocol to bismuth trioxide shown in the following examples.

Ratio of Example Alcohol Alcohol to Number Bismuth Trioxide 6 Glycerol 10:1 7- Trimethylolpropane. 4:1 8. Trimethylolethane 5:1 Pentaerythritol 3:1

Using the procedure of Example 1, additional catalyst compositions are prepared in accordance with the invention using antimony and bismuth compounds other than the oxides. The specific metallic compound as well as the ratios of glycerol to metallic compound are shown in the following examples.

Ratio of Example Metallic Compounds Glycerol to Number Metallic Compound 10 Antimony trichloride 11 Antimony oxychloride 12 Tris(2-chloroethyl)antimonite Bismuth trichloride 15 Tris(2-ch1oropropyl)bismuthite EXAMPLE 16 This example illustrates the preparation of flame retardant rigid urethane foams using the product of the present invention as a catalyst.

A rigid urethane foam is produced from:

a polyester prepared from 7.6 moles of glycerine, 4 moles of 1,4,5,6,7,7-hexachlorobicyclo(2,2,1)-5- heptene-2,3-dicarboxylic acid, and 2 moles of adipic acid reacted to an acid number of 5;

(e) 35 grams of trichlorofiuoromethane; and

(f) 30 grams of the reaction product of trimethylopropane and antimony trioxide prepared in accordance with the procedure of Example 2.

The foam expands and cures at room temperature to produce a self-extinguishing foam of normal resilience. Attempts to use antimony trioxide, sodium antimonate or sodium antimony tartrate as catalysts lead to friable foams. When using the reaction product of antimony trioxide and excess trimethylopropane as prepared in Example 2, no difiiculty in dissolving the material or obtaining a homogenous system is experienced.

Foam prepared in accordance with the above procedure is compared with foam prepared from an identical composition with the exception of using purified trimethylolpropane antimonite as the catalyst in an amount equivalent in antimony content to the 30 grams of reaction mixture above employed. The foam produced using the catalyst of Example 2 is as satisfactory in all respects as that produced using the pure trimethylolpropane antimonite. Additionally, the catalyst of Example 2 forms a uniform homogenous foam system more rapidly and efficiently than the pure trimethylolpropane antimonite and the results are more uniform and predictable.

EXAMPLE 17 The results obtained in Example 16 are reproduced by repeating the procedure of Example 16 except that the antimony trioxide is introduced into the trimethylolpropane used to prepare the polyester prior to the reaction with adipic acid. In this preparation, the entire five moles of trimethylolpropane is heated to the temperature range of one hundred and sixty to one hundred and eighty-five degrees centigrade in the presence of the antimony trioxide. Thereafter the heated trimethylolpropane containing the antimony ester is reacted with the adipic acid to prepare the polyester for use in the polyurethane foam preparation.

EXAMPLE 18 This example illustrates the preparation of flame retardant flexible foam.

The following components are mixed until a homogenous suspension occurs:

To the above ingredients, 149 grams of t-olylene diisocyanate isomers is added with rapid stirring. The liquid is poured into a mold and permitted to expand at room temperature for 3 minutes. The foam was placed in an oven for minutes at 75 C., crushed, and then cured for 1 hour at 120 C.

The resultant foam is resilient, tough and flame retardant. Heat aging 120" C. for two weeks shows no loss of resilience, while a similar sample without the reaction product of antimony trioxide and excess glycerol prepared in accordance with the procedure of Example 1 is totally degraded in two days.

The foam described above is. compared with foam prepared following an identical procedure with the exception of using pure glycerol antimonite in a quantity providing the same amount of antimony as that used in the above example. The foam prepared in accordance with the above example is fully as good as that prepared from the pure glycerol antimonite catalyst. In addition, the catalyst reaction product of Example 1 appeared to form a uniform mixture more rapidly.

The methods of this invention can also be applied to the reaction of the antimony and bismuth compounds with dihydric alcohols. However, the resulting compositions are much less desirable for the preparation of polyurethanes, polyesters, etc. However, the following ex amples exemplify such preparations.

EXAMPLE 19 Nine moles of propylene glycol and one mole of antimony trioxide are admixed and heated to a temperature range of one hundred and seventy to one hundred and seventy-five degrees centigrade. The water of reaction is removed from the composition over a period of three hours and fifteen minutes during which time the temperature of the reaction mixture rises to one hundred and eighty-seven degrees centigrade. The reactor contents are poured into a container and cooled to room temperature.

EXAMPLE 20 Five moles of diethylene glycol are mixed with one mole of antimony trioxide and heated to the temperature range of one hundred and ninety to two hundred degrees centigrade. Vacuum '(fourteen millimeters mercury absolute) is applied and the water of reaction is removed over a period of five and one-half hours, after which the reaction mixture is poured into a container and cooled to room temperature.

The catalyst compositions of the invention are employed in a catalytic amount. Generally, the proportion of metal compound can vary in the range of 0.01 to 0.1 part by weight of metal per part of polymeric reactant, i.e., polyester, polyether, and the like.

Various hydroxyl-containing polymers having a hydroxyl number of between about 25 and 900 can be used in the present invention, for example, a polyester, a polyether or mixtures thereof. The preferred hydroxyl-containing polymers of the present invention are the polyester-polyether mixtures wherein the polyester portion comprises fifty percent or more of the polyester-polyether mixture (i.e., when the polyester-polyether mixture is at least fifty percent by weight polyester). Excellent results are obtainable when less than fifty percent polyester is employed but supplementary additives may be desirable to render such a foam self-extinguishing. It is especially preferred in the present invention to use a mixed polyesterpolyether in the ratio of 50 to parts polyester to 15 to 35 parts polyether. It has been found that this particularly preferred range utilizes to best advantage the low cost of the polyethers, the low viscosity of the polyethers, and the desirable properties of the polyesters. Generally, the hydroxyl-containing polymers of the present invention have a molecular weight of from about 200 to about 4,000. v

The polyesters are the reaction products of a polyhydric alcohol and a polycarboxylic compound, said polycarboxylic compound being either a polycarboxylic acid, a polycarboxylic acid anhydride, a polycarboxylic acid ester, a polycarboxylic acid halide or mixtures thereof. Among the polycarboxylic compounds which may be used to form the polyester are: maleic acid; fumaric acid; phthalic acid; tetrachlorophthalic acid; and aliphatic acids such as oxalic, malonic, succinic, glutaric, adipic, and the like. Additional polycarboxylic compounds which may be used to form the polyester are Diels-Alder adducts of hexahalocyclopentadiene and a polycarboxylic compound,-

wherein the halogen is selected from the group consisting 9 of chlorine, bromine, fluorine and mixtures thereof, for example: 1,4,5,6,7,7-hexachlorobicyclo(2.2.1)--heptene- 2,3-dicarboxylic acid; 1,4,5,-tetrachloro-7,7-difluorobicyclo(2.2.1)-5-heptene-2,3-dicarb0xylic acid; l,4,5,'6,7,7-hex abromobicyclo(2.2.1)-5-heptene-2,3-dicarboxylic acid; 1,4, 5,6 tetrabromo-7,7-difluorobicyclo (2.2.1)-5-heptene-2,3- dicarboxylic acid; etc. Mixtures of any of the above polycarboxylic compounds may be employed.

To obtain a satisfactory rigid foam, at least a portion of the total polyhydric alcohol component should be a polyhydric alcohol containing at least three hydroxyl groups. This provides a means for branching the polyester. Where an even more rigid structure is desired, the whole alcohol component may be made up of a trifunctional alcohol such as glycerol. Where a less rigid final product is desired, a difunctional polyhydric alcohol such as ethylene glycol or 1,4-butanediol may be utilized as that part of the polyhydric alcohol component. Other glycols such as diethylene glycol, propylene glycol, and the like, can also be used. Among the polyhydric alcohols which can be used are glycerol, hexanetriol, butanetriol, trimethylol propane, trimethylol ethane, pentaerythritol, and the like. The ratio of the polyhydric alcohol such as glycol to the polybasic acid can be expressed as the hydroxylcarboxyl ratio, which may be defined as the number of moles of hydroxyl groups to the number of moles of carboxyl groups in a given weight of resin. This ratio may be varied over a wide range. Generally, however, a hydroxyl-carboxyl ratio of between 1.5:1 to 5:1 is employed.

Instead of employing a polycarboxylic compound which is a Diels-Alder adduct of hexahalocyclopentadiene and a polycarboxylic compound, we may employ a polyhydric alcohol which is a Diels-Alder adduct of hexahalocyclopentadiene and a polyhydric alcohol. This can be done by employing (A) a polyester resin comprised of the reaction product of (1) an adduct of hexahalocyclopentadiene and a polyhydric alcohol containing aliphatic carbon-to-carbon unsaturation, (2) a polycarboxylic compound, and (3) a polyhydric alcohol containing at least three hydroxyl groups. Typical adducts include: 2,3-dimethylol-l,4,5,6,7,7 hexachlorobicyclo(2.2.1)-5-heptene; 2,3-dimethylol-1,4,5, 6-tetrachloro 7,7 difluorobicyclo (2.2.l)-5-heptene, etc. These compounds and others are disclosed in US. Patent No. 3,007,958.

The preferred polyesters of the present invention are those which contain an adduct of hexahalocyclopentadiene coreacted in the polyester portion in view of the fact that they contain a large amount of stable chlorine, thereby enhancing the flame-retardant characteristics of the resultant foam. Particularly preferred are those polyesters wherein the adduct is reacted in the polycarboxylic portion of the polyester, due to lower cost, commercial availability and utility of the polycarboxylic adducts of hexahalocyclopentadiene.

The polyethers employed are the reaction products of (1) a polyhydric alcohol and/or a polycarboxylic acid, and (2) a monomeric 1,2-epoxide possessing a single -l,2- epoxy group, such as, for example, propylene oxide. The polyhydric alcohols and polycarboxylic acids which may be employed are any of the polyhydric alcohols and polycarboxylic acids hereinbefore listed. Examples of monomeric 1,2-epoxides include ethylene oxide, propylene oxide, butylene oxide, iso-butylene oxide, 2,3-epoxyhexane, epic-hlorohydrin, styrene oxide, glycidyl ether, glycidyl methyl sulfone, glycidyl methacrylate, glycidyl benzoate, glycidyl sorbate, glycidyl allyl phthalate, andthe like. The preferred monoepoxides are the monoepoxide-substituted hydrocarbons, the monoepoxy-substituted ethers, sulfides, sulfones and esters wherein the said compounds contain no more than eighteen carbon atoms. A lower alkylene oxide is preferably employed in rigid foams as the highercounterparts yield flexible rather than rigid products.

A large number of various organic diisocyanates can be used. The aromatic diisocyanates are more reactive and less toxic than the aliphatic members, and are consequently preferred. The compounds which are at present most readily available commercially are 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate and mixtures thereof. However, others may be used, among them methylene bis(4- phenylisocyanate), 3,3'-bitolylene-4,4'-diisocyanate, 3,3- dimethoxy 4,4 biphenylene diisocyanate, naphthalene- 1,5-diisocyanate, 1,3,5-benzene triisocyanate, polymethylene polyphenylisocyanate,-as well as the many impure or crude polyisocyanates that are commercially available, such as crude mixtures of methylene bis(4-phenylisocyanate).

The polyisocyanate concentration can be varied from about 75 to percent of isocyanato groups with respect to the total number of hydroxyl and carboxyl groups in the hydroxyl-containing polymer and foaming agent (if a foaming agent is employed). The preferred concentration is about one hundred percent.

Any foaming agent commonly used in the art can be employed. Suitable foaming agents are those materials capable of liberating gaseous products when heated, or when reacted with an isocyanate. The preferred foaming agents are the fiuorochlorocarbons boiling in the range of twenty to fifty degrees centigrade, and mixtures thereof, for example, trichlorofluoromethane, trichlorotrifiuoroethane, dichloromonofluoromethane, monochloroethane, monochloromonofiuoroethane, difluoromonochloroethane and difluorodichloroethane. Another foaming system which can be used is that comprised of tertiary alcohols in the presence of strong, concentrated acid catalysts. Examples of tertiary alcohols include: tertiary amyl alcohol; tertiary butyl alcohol; and the like. Examples of catalysts include: sulfuric acid; phosphoric acid; sulfonic acid; and aluminum chloride, etc. In addition, various secondary alcohols can be used such as: l-phenyl-l,2-ethanediol; 2- butanol; and 2-methyl-2,4-pcntanediol; and the like, preferably with strong, concentrated acid catalysts as above. Other foaming agents that can be used include the following: polycarboxylic acids; polycarboxylic acid anhydrides; dimethylol ureas, polymethyl phenols; formic acid and tetrahydroxymethylphosphonium chloride. In addition, mixtures of the above foaming agents may be employed.

Various additives can be incorporated which serve to provide different properties. For instance, antimony oxide can be used to improve fire-resistance, fillers, such as clay, calcium sulfate or ammonium phosphate may be added to lower cost, and improve density and fire-resistance; ingredients such as dyes may be added for color, and fibrous glass, asbestos, or synthetic fibers may be added for strength,

While the invention has been described with respect to certain specific embodiments, it will be recognized by those skilled in the art that many variations are possible within the scope of the invention.

We claim:

1. In a process for the preparation of a polyurethane composition, wherein at least one polymer selected from the grou consisting of a polyether and a polyester resin is reacted together with an organic polyisocyanate, the improvement which comprises reacting the polymer with the organic polyisocyanate in the presence of a catalytic amount of a catalytic composition consisting essentially of an antimony alcoholate containing linkages and a carrier therefor, prepared by reacting together an alcohol selected from the group consisting of trimethylolpropane and glycerol, and antimony trioxide; the reaction mixture for preparing the catalytic composi tion consisting essentially of the alcohol and antimony trioxide in a ratio which provides at least 1.5 moles of the alcohol for each unit atomic weight of antimony, the alcohol being present in said reaction mixture in an amount to provide a reaction medium during a reaction and to act as a carrier for the resultant reaction product, said reaction mixture after completing the reaction containing excess unreacted alcohol as a carrier for the reaction product and the reaction product being present therein.

2. The process of claim 1 wherein the alcohol is trimethylolpropane.

3. The process of claim 1 wherein the alcohol is glycerol.

4. The process of claim 1 when conducted in the presence of a foaming agent to produce a polyurethane foam.

1 2 References Cited UNITED STATES PATENTS 11/1963 Worsley ct al. 2602.5 4/1966 Hindersinn et a1 260-2.5

DONALD E. CZAJA, Primary Examiner.

M. FEIN, Assistant Examiner. 

